2005 TOYOTA 4RUNNER Power Train Problems

- The undercarriage and frame have had premature rusting for years. The car is otherwise in excellent condition due to my care of it over the last 20 years. 5 years ago, a service person at my local Toyota dealership said, "I'm really disappointed in Toyota, I've never seen rust like this." I have now recently been told by a local service shop that it's time to get a new car. The lines are all corroded for the power steering, etc, and he was unable to even "touch them," and said that the rust issue is no longer safe, and we shouldn't drive far from home. - We are now unable to drive the car much, as we live in the country and have far communities. With a [XXX] , we are unwilling to drive the car over 45 mph, or more than 10 miles for fear of an accident after reading about the manufacturing defect in this model of the 4-Runner. - It has not been inspected by the above stated people. - no warnings, I would not have know the vehicle had such severe premature rusting issues if it weren't for a service person telling me such. -My vehicle has under 140k miles on it, and I've taken exceptional care of it over the past 20 years. I could have sold it for 10k given its condition, and low mileage, but it is now likely worth nothing given the manufacturing defect which caused premature rusting. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

EXCESSIVE FRAME RUST AND UNDERBODY RUST. MOST WELD POINTS AND FRAME ASSEMBLY IS DEGRADING FROM RUST. TRANSMISSION COOLANT LINES HAVE CRACKED AND LEAKED.

EXCESSIVE UNDERBODY RUST, RUSTING FRAME JOINTS, AND ROTTING FRAME MEMBERS FROM THE INSIDE OUT.

Mileage: 198,500

VEHICLE HAS VERY EXCESSIVE FRAME RUST. HOLES THROUGHOUT ENTIRE FRAME MAKING THE VEHICLE UNSAFE TO DRIVE. RUSTING FROM THE INSIDE OUT DUE TO NEGLIGENCE ON TOYOTAS PART. THIS VEHICLE HAS THE SAME EXACT FRAME THAT WAS RECALLED ON THE TACOMAS, TUNDRAS AND SEQUOIAS. PLEASE TELL ME WHY THE 4RUNNER WAS LEFT OUT?

Mileage: 130,000

2005 TOYOTA 4RUNNER SR5 WAS TAKEN INTO A CERTIFIED TOYOTA MECHANIC FOR INSPECTION AND THE MECHANIC SHOWED ME THE UNDERCARRIAGE OF THE VEHICLE, NAMELY THE FRAME AND OTHER ASSOCIATED PARTS. HE WARNED THAT IT WOULD BE DIFFICULT TO PERFORM MAINTENANCE ON THE VEHICLE IF THE FRAME IS ROTTED THROUGH. THE VEHICLE WAS PUT ON A LIFT FOR INSPECTION.

Mileage: 228,000

THE REAR AXLE RUSTED SO BADLY THAT IT STARTED FLAKING APART. THE FRAME IS RUSTED SEVERELY IN THE AREAS WHERE THE REAR SUSPENSION COMPONENTS ATTACH. THE GAS TANK SKID PLATE RUSTED UNTIL IT BEGAN TO FALL OFF WHILE DRIVING DOWN THE ROAD AND ALL OF THE AREAS WHERE IT WAS BOLTED TO THE FRAME COMPLETELY RUSTED OUT. THE EXHAUST ALSO RUSTED THROUGH BEHIND THE MUFFLER CAUSING IT TO FALL OFF WHILE DRIVING DOWN THE ROAD. THERE ARE HOLES IN MULTIPLE AREAS OF THE FRAME. I HAD TO GRIND,CHIP, AND WIRE BRUSH THE FRAME WITH THE VEHICLE ON JACK STANDS IN ORDER TO REPAINT EVERYTHING AND KEEP MY VEHICLE GOING. THIS TOOK OVER 100 HOURS OF LABOR JUST TO COMPETE. I ALSO HAD TO REPLACE THE EXHAUST AND THE GAS TANK SKID PLATE. ALL OF THE BOLTS FOR THE SKID PLATES ON THE BOTTOM OF THE VEHICLE WERE COMPLETELY RUSTED THROUGH AND COULD NOT BE REMOVED WITHOUT FALLING APART AND LEAVING HALF THE BOLT IN THE FRAME. THE XREAS SUSPENSION SYSTEM WHICH RUNS HYDRAULIC LINES AROUND THE FRAME ALSO RUSTED APART AND LEAKED FLUID ALL OVER EVERYTHING. THE BOLTS WERE ALL HEAVILY RUSTED AND COULD NOT BE REMOVED TO GET THE LINES OFF THE FRAME. THE FRAME ON THIS VEHICLE WAS NOT ADEQUATELY COATED TO PREVENT IT FROM RUSTING. THIS NEEDED TO BE DONE WITH APPROXIMATELY 100,000 MILES ON THE VEHICLE.

Mileage: 100,000

STSTIONARY REAR AXEL HOUSING RUSTED -LEAKING OIL-INFERIOR STEAL JUST LIKE THE FRAME THAT WAS REPLACED

Mileage: 127,000

EXCESIVE RUST UNDER BODY. EXHAUST SYSTEM AND FRAME.

TL* THE CONTACT OWNS A 2005 TOYOTA 4RUNNER. WHILE DRIVING 70 MPH, THE VEHICLE LOST POWER. IN ADDITION, THE ACCELERATOR PEDAL WAS DEPRESSED, BUT THE VEHICLE FAILED TO ACCELERATE. THE CHECK ENGINE AND VSC WARNING LIGHTS ILLUMINATED. THE VEHICLE WAS TAKEN TO AN AUTO STORE WHERE A TECHNICIAN PULLED UP DIAGNOSTIC TROUBLE CODES. THE CONTACT SPOKE WITH A LOCAL DEALER WHO STATED THAT, BASED ON THE CODES PROVIDED, THE VEHICLE WOULD BE REPAIRED UNDER NHTSA CAMPAIGN NUMBER: 05V123000 (ENGINE AND ENGINE COOLING). THE VIN WAS NOT INCLUDED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 103,000.

Mileage: 103,000

TL* THE CONTACT OWNS A 2005 TOYOTA 4RUNNER. WHEN THE VEHICLE CAME TO A COMPLETE STOP, THERE WAS A TWO SECOND DELAY BEFORE THE VEHICLE JOLTED. THE CONTACT STATED THAT IT FELT AS THOUGH SOMEONE HAD REAR-ENDED THE VEHICLE. THE CONTACT STATED THAT THE FAILURE OCCURRED INTERMITTENTLY AND BECAME PROGRESSIVELY WORSE OVER TIME. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE DRIVESHAFT WAS LUBRICATED; HOWEVER, THE FAILURE RECURRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 150,000.

Mileage: 150,000

LOW MILEAGE CAR AND PARTS OF THE FRAME ARE FALLING A PART. DEALER REFUSES TO SERVICE CAR AS IT IS UNSAFE. TOYOTA SAYS THEY HAVE NO PROBLEMS WITH THE 4RUNNERS RUSTING JUST THERE TRUCKS AT THIS TIME...?

I HAVE A 2005 TOYOTA 4RUNNER AND IT HAS A LOUD CLUNK IN THE DRIVETRAIN EVERY TIME I STOP.WHEN IT CLUNKS IT ALSO LUNGES FORWARD CAUSING A FEW CLOSE CALLS I HAVE ADDRESSED THIS ISSUE WITH TOYOTA AND THEY SAY IT IS A NORMAL OPERATING CHARACTERISTIC. THE PROBLEM OCCURS IN THE 03-06 4RUNNERS,TACOMAS AND LEXUS GX470 TOYOTA HAS A T.S.B ON THE LEXUS MODEL ONLY NOT THE TOYOTA 4RUNNERS OR TACOMAS WHICH MEANS AT LEAST TO ME THAT IT IS A DEFECT!!! I HAVE CONTACTED THE DEALERSHIP AND THEY SAY THEIR IS NO TSB SO THEY CANT DO ANYTHING I CONTACTED TOYOTA AND GOT NO RESPONSE. IF THEY WILL FIX THE LEXUS VERSION WHY NOT THE TOYOTA VERSION??? *TR

Mileage: 125,000

2005 TOYOTA 4-RUNNER SPORT EDITION. HAD CAR PARKED IN DRIVEWAY. CAR WAS IN PARK WITH NO KEY IN THE IGNITION. 4-YEAR OLD CHILD CLIMBED INTO CAR AND PUT CAR GEAR-SHFT INTO NEUTRAL (NO KEY IN IGNITION AND FOOT WAS NOT ON BRAKE PEDAL). CAR ROLLED OUT OF DRIVEWAY INTO A BUSY ROAD. ANOTHER CAR NEARLY HIT THE 4-RUNNER. DRIVER OF OTHER VEHICLE STOPPED AND HALTED OTHER TRAFFIC BY HONKING THEIR HORN. OWNER OF 4-RUNNER HEARD HONKING, CAME OUT OF HOUSE AND FOUND 4-RUNNER SITTING ACROSS THE ROAD WITH THE 4-YEAR OLD CHILD STILL IN IT. CONDITION OF PUTTING 4-RUNNER INTO NEUTRAL WITHOUT KEY OR FOOT ON BRAKE PEDAL WAS TESTED SEVERAL MORE TIMES AND FOUND TO BE REPEATABLE. *TR

Mileage: 62,800

THE VEHICLE RPMS WOULD GO UP BUT THE CAR WOULD BARLEY MOVE, OR WHILE DRIVING GOING TO ACCELERATE THE VEHICLE WOULD NOT GO FASTER TO ENGAGE IN TRAFFIC, CORROSION OF PINS IN THE TRANSMISSION WIRING HARNESS THAT CONNECTS TO THE ENGINE WIRING HARNESS. THIS HARNESS IS ALSO TIED TO THE ABS, TRACTION CONTROL. IT CAUSES THE VEHICLE TO BECOME UNSAFE WHEN DRIVING AS IF IT ACTS UP YOU CANNOT ACCELERATE AND SORT OF CHUGS ALONG. DANGEROUS IN ON RAMP AND TRAFFIC SITUATIONS. THIS ALSO CAUSED THE SOLENOID IN THE TRANSMISSION TO SHORT OUT AS IT WAS HANGING UP ON THE SHIFT WHICH CAUSED A CLUNKING SOUND. THE TRANSMISSION WIRE HARNESS WAS REPLACED WHICH SHOWED 3 CORRODED PINS. THE SOLENOID IN THE TRANSMISSION WAS ALSO REPLACED. *TR

Mileage: 90,000

WHEN BRINGING VEHICLE TO A STOP, THERE IS A VERY LOUD CLUNK THAT CAN BE PHYSICALLY FELT SHUDDERING THROUGH THE ENTIRE VEHICLE. MANY MANY TRIPS TO THE DEALER RESULTED IN NOTHING. THERE IS A TSB FOR THE LEXUS EQUIVALENT OF THE 4RUNNER WITH THIS PROBLEM. THIS MEANS THEY ADMIT THERE IS A PROBLEM, BUT REFUSE TO ACKNOWLEDGE IT ON NON-LEXUS VEHICLES. UNACCEPTABLE. IF THE DRIVESHAFT IS IMPACTING THAT HARD EVERY TIME THE VEHICLE STOPS, IT IS A MATTER OF TIME BEFORE EXCESSIVE WEAR WILL CAUSE A SAFETY ISSUE. *TR

Mileage: 1

WHEN COMING TO A STOP VEHICLE TENDS TO SHIFT INTO FIRST GEAR LATE, RIGHT AT STOPPING AND IT FEELS LIKE A BUMP OR SOMEONE HITTING YOU FROM BEHIND. THIS DEPENDS ON HOW FAST THE VEHICLE IS STOPPED. IF STOPPED FASTER, THE VEHICLE NEVER SHIFTS INTO FIRST GEAR AT STOPPING. AFTER THE BRAKE IS RELEASED THE VEHICLE FEELS AS IF SHIFTING FROM SECOND TO FIRST GEAR. MANUALLY DOWN SHIFTING THE VEHICLE IN ALL GEARS FEELS NORMAL EXCEPT FROM SECOND TO FIRST. THERE IS A HESITATION BETWEEN THESE GEARS, THE VEHICLE COAST AS IF IN NEUTRAL FOR ABOUT TWO SECONDS THEN SHIFTS INTO FIRST GEAR. THIS WEBSITE ALSO DESCRIBES THE "BUMP" FEEL FROM OTHER OWNERS, SEARCH FOR "BUMP" HTTP://TOWNHALL-TALK.EDMUNDS.COM/DIRECT/VIEW/.F0DACC5/175. *TR

Mileage: 100,000

EVERY SO OFTEN MY 2005 TOYOTA 4-RUNNER WILL LURCH FORWARD AT A STOP. ITS LIKE THE VEHICLE IS BEING REARENDED. THIS OCCURS WITHOUT WARNING AND AT RANDOM TIMES DURING A TYPICAL DAY. THE TRANSMISSION WILL ALSO LOCK IN 4TH GEAR IF WHILE DRIVING ON THE INTERSTATE THE VEHICLE SLOW SUDDENLY - THIS IS CORRECTED BY PULLING OFF THE INTERSTATE, SHUTTING DOWN THE VEHICLE AND WAITING A FEW MOMENTS. *TR

I AM WRITING TODAY TO ALERT YOU TO A POTENTIAL ACCELERATOR PROBLEM WITH THE 2005 TOYOTA 4RUNNER SUV. IN MID-DECEMBER, MY HUSBAND AND I WERE DRIVING ON THE HIGHWAY WHEN THE CAR INEXPLICABLY ACCELERATED, GOING FROM APPROXIMATELY 40 MPH TO ABOUT 60 MPH WITHIN A MATTER OF SECONDS. MY HUSBAND, WHO HAS HAD PROFESSIONAL DRIVING INSTRUCTION, PUT THE CAR INTO NEUTRAL AND WAS ABLE TO SLOW THE CAR DOWN, AT WHICH POINT THE ACCELERATOR (WHICH WAS MOVING TOWARDS THE FLOOR WITHOUT A FOOT ON IT) POPPED BACK UP AND THE BRAKES BEGAN WORKING AGAIN. HOWEVER, WITHIN THIS SAME JOURNEY, THIS SAME ACCELERATOR PROGRAM OCCURRED TWO ADDITIONAL TIMES. WE IMMEDIATELY TOOK THE SUV TO TOYOTA OF ALEXANDRIA IN VIRGINIA AND EXPLAINED WHAT HAPPENED. THEY NOTIFIED US THAT OUR CAR WAS NOT SUBJECT TO A RECALL FOR ACCELERATOR PROBLEMS BUT, BASED ON OUR CONCERNS, AGREED TO EXAMINE THE SUV. TO THEIR CREDIT, THEY DID CALL IN A CORPORATE INSPECTOR TO EXAMINE THE DISSEMBLED DRIVE TRAIN WHO IN TURN DETERMINED THAT AN ACCUMULATION OF OIL IN THE DIFFERENTIALS CAUSED THE CARS COMPUTER TO MISREAD ACCELERATION AND DECELERATION INFORMATION. DESPITE THIS DIAGNOSIS -- AND SUBSEQUENT REPLACEMENT OF THE DRIVE TRAIN AND REAR DIFFERENTIALS -- TOYOTA MECHANICS WERE NEVER ABLE TO REPLICATE THE ACCELERATION PROBLEM THAT WE EXPERIENCED. AFTER TALKING TO SEVERAL TOYOTA REPRESENTATIVES, AS WELL AS A NUMBER OF INDEPENDENT MECHANICS, WE WERE ADVISED TO PURSUE ARBITRATION WITH TOYOTA AND ARE CURRENTLY ENTRENCHED IN THAT PROCESS. IN THE INTERIM, WE ARE USING THE CAR ONLY FOR LOCAL JOURNEYS OUR OF CONCERN THAT THIS ACCELERATOR PROBLEM COULD REOCCUR. I AM WRITING TODAY TO INFORM YOU OF THE PROBLEM SO THAT YOU HAVE A RECORD THAT TOYOTA'S ACCELERATOR PROBLEMS MAY EXTEND BEYOND THE CARS/SUVS INCLUDED IN THE RECENT RECALL. *TR

Mileage: 83,000

1. HAPPENED SINCE ABOUT 15-20K MILES ON MY 2005 4RUNNER (I'M THE FIRST AND ONLY OWNER). 2. OCCURS WHEN COMING TO A STOP, LARGE CLUNK SOUND AND VEHICLE JOLTS FORWARD RIGHT AFTER A FULL STOP. 3. NOTHING HAS BEEN DONE TO CORRECT THE FAILURE. EACH TIME THE TOYOTA DEALER SERVICE TECH TAKES IT FOR A RIDE THEY CANNOT REPLICATE IT, I WENT ONCE AND WAS NOT ABLE TO REPLICATE IT AT THAT TIME. HOWEVER, THERE ARE NUMEROUS ONLINE FORUM DISCUSSIONS ABOUT THE ISSUE (SEE THIS ONE: HTTP://WWW.TUNDRASOLUTIONS.COM/FORUMS/4RUNNER/53302-4RUNNER-V8-CLUNK-IN-DRIVETRAIN/). APPARENTLY A RECALL FIX FOR THE LEXUS 470 (SAME AS A TOYOTA 4RUNNER LIKE MINE) HAS BEEN PROVIDED FOR LEXUS OWNERS BUT NOT FOR TOYOTA OWNERS. THE PARTS TO SOLVE THE ISSUE ARE IDENTICAL. TOYOTA DEALER SERVICE DEPARTMENT STATED UNLESS TOYOTA MOTOR CORP. ACTUALLY ISSUES A RECALL AND PROVIDES DETAILS ON A FIX, THEY ARE NOT ABLE TO DO ANYTHING SINCE WE CANNOT REPLICATE IT WHEN THEY ARE SERVICING MY 4RUNNER. *TR

Mileage: 15,000

SEVERAL TIMES A DAY WHEN I COME TO A STOP IN MY 2005 4RUNNER I HEAR A CLUNK AND IT FEELS LIKE SOMEONE HAS JUST REAR ENDED ME. THIS HAS HAPPENED SINCE I BOUGHT THE VEHICLE AND IS GETTING WORSE. LEXUS HAS A TSB FOR THIS EXACT SAME COMPLAINT YET TOYOTA PRODUCTS DO NOT. WHY IS THAT? TSB#DL002-07. *TR

DRIVESHAFT CLUNKS AFTER COMING TO A STOP ALSO ON ACCELERATION FROM A STOP. *TR

Mileage: 30,000

IN GENERAL, WHEN I PULL UP TO A STOP I SOMETIMES FEEL A CLUNK. THEN, WHEN I START AGAIN, IT FEELS LIKE THE BRAKE RELEASE IS DELAYED WITH ANOTHER CLUNK. THERE'S A FEW LEXUS GX470 OWNERS (SAME ENGINE AND DRIVETRAIN AS 4RUNNER) THAT ARE COMPLAINING AT OTHER SITES. I'VE BEEN TOLD THE TWO PIECE DRIVESHAFT GETS AIR COMPRESSED INSIDE, AND WHEN THE COMPRESSION LEAKS OUT, YOU GET THE CLUNK. LEXUS IS APPARENTLY FIXING THE PROBLEM. *JB

Mileage: 34,090